1t-3.5t R Series Internal Combustion Counterbalanced ...

1 R Series Internal Combustion Counterbalanced Forklift Truck SERVICE MANUAL HANGCHA GROUP CO., LTD. Jun. 2011 5th EDITION Foreword The manual is the introduction of structure, working principle and serving of R Series Internal Combustion counterbalance forklift truck. For safety and performance of truck, all in charge of operation, maintenance and management must read and comprehend this manual well. The manual also applies to container fork-lift trucks. It is forbidden anybody without training and qualification to maintain. Our product design will update and perform better, so the content in this manual may be not the same as the forklift you owned. If you have any questions please keep touches with HANGCHA GROUP CO., LTD. sales department or let the agents know. Jun.

2 2011 5th edition HANGCHA GROUP CO., LTD. Content Foreword I. Power System 1 1. Engine for Forklift 1 2. NISSAN K21 K25 gasoline 3 3. C240 PKJ-30 Diesel 12 4. TD27AA diesel 14 II. Hydrodynamic transmission,torque converter 17 1. Summary 17 2. Data 18 3.

3 Working principles 19 4. Structure 21 5. Notice about installation and usage 30 6. Cause and solutions 30 III. Driving axle 31 1. Date 31 2. Trouble diagnoses and corrections 31 3. Assembly and disassembly of driving axle 32 4.

4 Axle shaft and wheel hub 33 5. Bearing adjusting 34 IV. Steering axle 36 1. General specifications 36 2. Trouble diagnoses corrections 36 3. Steering axle 38 4. Kingpin and steering spindle. 38 5. Wheel bearing adjustment 38 V.

5 Steering system 39 1. Data 39 diagnoses 39 3. Summarize 40 4. Install steering system 42 VI. Brake system 43 and diagnoses and corrections 43 2. Summary 44 system 48 1 Data 48 2 Trouble diagnoses and corrections 50 3.

6 Main pump 52 4. Control valve 55 5. Hydraulic piping 57 system 59 1. Assemble debugging data 59 2. Trouble diagnoses and corrections 60 3. Summary 63 4. Removal and adjustment 69 5.

7 Disassembly and installation of lifting jack 73 6 Disassembly and installation of tilting cylinder 74 7. Noticing proceeding of debugging 75 system 77 1 I. Power System 1. Engine for Forklift Engine Parameter Gasoline K21(Japan) K25(Japan) Rated output kW 37 44 Rated rotate speed r/min 2300 2500 Max. torque N m / Speed r/min 142/1600 179/1600 Service weight kg 158 161 Forklift truck model CPQ10/15/18N- RW21 CPQD10/15/18N- RW21 CPQ20/25/30/35N -RW22 CPQD20/25/30/35N -RW22 CPQD20/25/30/35N - RW22A CPQD20/25/30/35N- RW22B Engine Parameter Diesel C240 PKJ-20 C240 PKJ-30 Rated output kW 35 35 Rated rotate speed r/min 2500 2500 Max.

8 Torque N m / Speed r/min 139/1800 139/1800 Service weight kg 252 252 Forklift truck model CPC10/15/18N -RW9 CPCD10/15/18N -RW9 CPC20/25/30/35N -RW9 CPCD20/25/30/35N-RW9 CPC20/25/30/35N-RW9B CPCD20/25/30/35N-RW9B CPC10/15/18N-RW10 CPCD10/15/18N-RW10 CPC20/25/30/35N-RW10 CPCD20/25/30/35N-RW10 CPC20/25/30/35N-RW10B CPCD20/25/30/355N-RW10B Engine Parameter Gasoline LPG single fuel Diesel BY491GP Baiyang IMPCO A498BT1-1 Rated output kW 38 50 Rated rotate speed r/min 2600 2500 2400 Max. torque N m / Speed r/min 161/1800-2200 189 /1600 186/1600 1800 Forklift truck model CPQ(D)10/15/18N-RW7 CPQ(D)20/25/30N-RW7 CPQD20/25N-RW26-Y CPQD30/35N-RW26-Y CPCD20/25N-RW27 CPCD30/35N-RW27 2 Engine Parameter Diesel Diesel (YANMAR) TD27AA NiSSAN 4 TNE92-HRJ 4 TNE98-BQFLC Rated output kW Rated rotate speed r/min 2300 2450 2300 Max.

9 Torque N m / Speed r/min 160/2300 / 1600 206 /1700 Service weight kg 243 194 194 Forklift truck model CPCD20/25N -RW15A CPCD30/35N -RW15A CPCD10/15/18N-RW32 CPCD20/25N-RW32 CPCD30/35N-RW32 CPCD20/25N-RW33 CPCD20/25N-RW33B CPCD20/25N-RW33M CPCD30/35N-RW33 CPCD30/35N-RW33B CPCD30/35N-RW33M Specifications, structure and maintenance methods for engine see ENGINE MAINTENANCE MANUAL. Specifications, structure and maintenance methods for model TD27AA engine see KEY COMPONENTS IMPORTED FROM NISSAN SERVICE MANUAL . Check value of end gas after maintaining engine, and the value must be according to following figure: Engine power (kW) CO (g/kW h) HC (g/kW h) NO2 (g/kW h) PT(particle) (g/kW h) 18 P<37 8 37 P<75 5 7 3 2. NISSAN K21 K25 gasoline Specification Specification Gasoline Model K21 K25 Type Water cooled, four cycle, in-line overhead valve type Cylinder: No.

10 Stroke mm 4 89 4 89 Displacement L Direction of rotation Clockwise cooling fan Firing order 1-3-4-2 Valve clearance mm Intake(Hot) Exhaust(Hot) Cooling System Water-cooled, forced circulation Lubrication System Forced Lubrication Main component Carburetor model 210030-41 210030-42 Fuel pump Film-type Air clear Paper element Oil pump Gear type Oil filter Paper element Water pump Centrifugal Thermostat Wax-pellet type Standard clearance of switchboard 0 35-0 45 Spark plug Type FR2A-D Plug gap(mm) Generator Type A7T03371 Voltage V 12 current A 35 Starter Type M000T65381 (Planetary gear type) Voltage V 12 Output power kW Governor Type Pneumatic Speed control system By controlling mix. tare amount Operation of control mechanizing By suction negative pressure Max. Engine speed under no-laden 3600 r/min Max.